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A-Controller

Manual

E 5.96012.02a
Title Manual
Product A-Controller
Version 5.96012.02a

Copyright These operating instructions may be copied by the owner


in any quantity but only for internal use. For other purposes
these operating instructions and extracts thereof must not
be copied or reproduced.
Use and disclosure of information contained in these oper-
ating instructions are not permitted.
Designations and company marks contained in these op-
erating instructions may be brand names, the use of which
by third parties for their own purposes may violate the
rights of the holders.
Obligatory These operating instructions are part of the equipment/ma-
chine. These operating instructions must be available to
the operator at all times and must be in a legible condition.
If the equipment/machine is sold or moved to a different lo-
cation these operating instructions must be passed on by
the owner together with the equipment/machine.
After any sale of the equipment/machine this original and
all copies must be handed over to the buyer. After disposal
or any other end of use this original and all copies must be
destroyed.
When the present operating instructions are handed over,
corresponding sets of operating instructions of a previous
version are automatically invalidated. Please notice that
specifications/data/information are current values ac-
cording to the printing date. These statements are not
legally binding according to the measurement, computa-
tion and calculations.
Baumüller Nürnberg GmbH reserves the right, in develop-
ing its products further, to change the technical specifica-
tions and the handling of the products concerned without
prior notice.
No liability can be accepted concerning the correctness of
the operating instructions unless otherwise specified in the
General Conditions of Sale and Delivery.
Manufacturer Baumüller Nürnberg GmbH
Ostendstr. 80 - 90
D-90482 Nürnberg
Germany
Tel. +49 9 11 54 32 - 0 Fax: +49 9 11 54 32 - 1 30
www.baumueller.de
Table of contents

TABLE OF CONTENTS

1 Safety Notes ........................................................................................................ 7

2 Technical Data .................................................................................................... 9


2.1 General ................................................................................................................................... 9
2.2 Electrical data ....................................................................................................................... 10
2.3 Type code ............................................................................................................................. 11

3 Transportation, Unpacking .............................................................................. 13

4 Assembly ........................................................................................................... 15
4.1 Dimensions ........................................................................................................................... 15
4.2 Assembly notes .................................................................................................................... 16

5 Installation ......................................................................................................... 17
5.1 Danger installation ................................................................................................................ 17
5.2 Checks before installation .................................................................................................... 18
5.3 Display .................................................................................................................................. 19
5.4 Connection diagram ............................................................................................................. 20
5.5 Operating data store BEDAS ................................................................................................ 22
5.6 Brushless tachometer generator cable ................................................................................. 24
5.7 Accessories .......................................................................................................................... 26

6 Commissioning ................................................................................................. 27
6.1 Danger information ............................................................................................................... 27
6.2 Initial commissioning of the drive system ............................................................................. 30

7 Maintenance ...................................................................................................... 33
7.1 Maintenance information ...................................................................................................... 33
7.2 Troubleshooting .................................................................................................................... 34
7.3 Disposal ................................................................................................................................ 36

8 Appendix ........................................................................................................... 37
8.1 Manufacturer Declaration ..................................................................................................... 37
8.2 General Conditions of Sale and Delivery .............................................................................. 38
8.3 Index ..................................................................................................................................... 41

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Table of contents

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Abbreviations

ABBREVIATIONS

AC Alternating current
AM Asynchronous motor
BB Ready for use
BEDAS Operating data store
BUM Baumotronic Converter Mono Power Unit
BUS Baumotronic Converter Servo Power Unit
DC Direct current
DIN German Standardization Institute (Deutsches
Institut für Normung e.V.)
DS Three-phase current
EMC Electromagnetic compatibility
FBS BEDAS missing
FLG Fault in position encoder signal
FPH Missing phase
FTO Fault in tachometer generator signal
HS Main contactor
HSE Main contactor ON
HSF Main contactor enable
IZK Overcurrent in DC link
LED Light emitting diode
LT Power unit
NMX Maximum RPM exceeded
RS Controller disable
SGR Current limit reached
SM Synchronous motor
TA Ambient operating temperature
TBA Overtemperature of chopper resistor
tH Ramp-up/ramp-down time
TKK Overtemperature of heat sink
TMO Overtemperature of motor
UVS Supply voltage too low
UZK DC link voltage
VDE German Association of Electrical Engineers
(Verein deutscher Elektrotechniker)

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Safety Notes

1 SAFETY NOTES

General information

These operating instructions contain the information required for the application as directed of the prod-
ucts described herein. The document is intended for specially trained, skilled personnel who are well-
versed in all warnings and maintenance activities.
The units are manufactured using the state-of-the-art technology and are safe in operation. They can be
installed safely and commissioned and function without problems if the safety information below is ob-
served.

DANGER

When operating this electrical unit, some parts of the equipment always carry dangerous voltage.
Ignoring these safety instructions and warnings may result in death, serious personal injury and/or
damage to material assets.
Only qualified personnel who are familiar with the safety information, assembly, operation and
maintenance instructions may carry out work on this unit.

Danger information

One the one hand, the information below is for you own personal safety and on the other to prevent
damage to the described products or to other connected units.

In the context of the operating instructions and the information on the products themselves, the terms
used have the following meanings:

DANGER

This means that death, severe personal injury or considerable damage to material assets
will occur, unless appropriate safety measures are taken.

WARNING

This means that death, severe personal injury or considerable damage to material assets
may occur, unless appropriate safety measures are taken.

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Safety Notes

NOTE

This draws your attention to important information about the product, handling of the product or to
a particular section of the documentation.

Qualified personnel

In the sense of the safety-relevant information in this document or on the products themselves, qualified
personnel are considered to be persons who are familiar with setting up, assembling, commissioning and
operating the product and who have qualifications appropriate to their activities.
y Trained or instructed or authorized to commission, ground and mark circuits and equipment in
accordance with recognized safety standards.
y Trained or instructed in accordance with recognized safety standards in the care and use of
appropriate safety equipment.

Application as directed

WARNING

You may only use the unit/system for the purposes specified in the operating instructions and in
conjunction with the third-party equipment and components recommended or authorized by
BAUMÜLLER NÜRNBERG GmbH.
For safety reasons, you must not change or add components on/to the unit. The operator must report
immediately any changes that occur which adversely affect the safety of the unit/system.

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Technical Data

2 TECHNICAL DATA

2.1 General

Closed-loop control

y Closed-loop controller for synchronous motors with brushless tachometer generators, position en-
coders
y Controller structure designed for current-controlled speed limiting system
y The controller provides:
– excellent concentricity properties
– high control dynamic response and rigidity across the entire RPM range
y Inputs:
– Controller enable
– Reset
– Two specified value inputs
– External current limitation
– Motor thermal relay
y Outputs:
– Two relay contacts
Ready for use message
programmable message: the relay rises either
– at controller enable
– at n = 0
– with an overcurrent/earth fault/transistor fault
– with a missing phase in the feed (BUM 60 only)
– in the case of intermediate circuit overvoltage or ballast resistor overtemperature
(BUM 60 only)
– in the case of overtemperature of the motor
– if the position encoder signals are missing
– in the case of overtemperature of the heatsink
– in the case of overloading of the 15-V voltage supply
– if the converter was run at the current limit for longer than 2 s
– if BEDAS is missing
– if the tachometer generator signals are missing
– if the maximum RPM is exceeded (by more than 20%)

y Two analog outputs


Iset display (10 V, bipolar)
nact display (10 V, bipolar)
y Miscellaneous
– Ambient operating temperature TA 0 ... +45° C
– Temperature of coolant (50 mm below bottom edge) Tcoolant 35° C
– Storage temperature range -30° C ... +85° C

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Technical Data

2.2 Electrical data

The data of the power unit depends on the basic unit and is described in the relevant documentation.

Technical data of the closed-loop controller:

Current set value Iset an X8:7 10 V at peak power unit current

Speed set value nset 0 ... ±10 V


Adaption * 5 V ... 11.5 V
nset additional 0 ... ±10 V
Integrator ramp-up and ramp-down time tH * 9 ms ... 250 ms

Speed actual value at X8:5 nist


nmax ≤ 3000 min-1 3.3 V / 1000 min-1 ±10 %
nmax ≥ 3000 min -1 1.65 V / 1000 min-1 ±10 %

Max. speed nmax motor-specific


Speed monitoring at 120 % of nmax

External current limitation


Standard 0.1 Is
Variable (Option) 0 ... 100 % IS
Max. current limited for * 0.3 / 0.5 / 1 / 2 s

Messages
Ready for use X8:3 and 4
Programmable function X8:1 and 2

Reset X8:10 and 11

Controller enable RF undelayed


Controller disable „braked OFF“ for 200 ms
Controller disable „unbraked OFF“ undelayed

Ready for use and programmable function


Contacts can be loaded with 24 V / 1 A

Errors displayed via 12 LED

* Using the operating data store (BEDAS), individual adaptation is possible at the factory to the
motor, machine and cooling conditions.
The default settings are printed in bold type.

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Technical Data

2.3 Type code

NOTE

With the type code:

Type code Mono power unit: BUM 60 - 30/60-31-B-002-A-0100-L


with controller: BUM 60 A - SM - 0100
an unit type exists for 230 VAC supply and analog controller which is fully compatible to the former BUM
25.
Only with this unit type
y the BEDAS and
y the programmable function outputs
are compatible with the last version of the BUM 25.

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Technical Data

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Transportation, Unpacking

3 TRANSPORTATION, UNPACKING

The units are packed at the factory in accordance with the order.
You should avoid jarring packages in transit or jolting them, e.g. when setting them down on the ground.
After unpacking the package(s) and checking that the shipment is complete, you can start assembly.
Fibre board, cartridge paper and/or wood are used as packaging materials and they can be disposed of
in accordance with local regulations.
Report any damage in transit without delay.

DANGER

If the unit has been damaged in transit, do not connect it to the mains until appropriate high-voltage
testing has been carried out.
Ignoring this information can result in death, severe personal injury, or considerable damage to prop-
erty

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Transportation, Unpacking

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Assembly

4 ASSEMBLY

4.1 Dimensions

BUS 6 A - SM (cassette version)

Plug-in module depth

y BUS 6 and BUM 62: 128.5 mm


y BUM 63/64: 131.0 mm
You can only determine the total depth in conjunction with the basic unit; you must also take into ac-
count the dimensions of the plug-in connectors used (approximately 40 mm).

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Assembly

4.2 Assembly notes

WARNING

The user is responsible for the assembly of the converter power unit, the motor and the other compo-
nents according to applicable safety standards (e.g. DIN, VDE) and all other relevant national or local
regulations regarding conductor dimensions and fusing, grounding, circuit breakers, overcurrent pro-
tection etc.

The units are protected from direct contact by being installed in commercially available switching cab-
inets that meet the minimum protection requirements of preliminary standard EN 50178/VDE 0160/
11.94, Section 5.2.4.

BUS 6 A - SM
Plug-in the controller cassette in the designed space of the unit and attach the cassette with its 2 screws.

NOTE

Do not plug-in the cassette when voltage is supplied.

BUS 60 A - SM
The controller is mounted on the unit.

The installation of the units is described in a separate documentation.

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Installation

5 INSTALLATION

5.1 Danger installation

WARNING

This equipment carries a dangerously high voltage and has dangerous rotating parts (fans). Ignoring
the safety and warning information may result in death, severe personal injury or damage to property.

The machine operator is responsible for mounting the power unit, the motor, the transformer and any
other equipment in accordance with appropriate safety regulations (e.g. DIN, VDE); equally, you must
ensure that all other relevant national and local regulations are met with regard to cable ratings and
protection, grounding, disconnectors, overcurrent protection, etc.

The DC link carries a voltage! It is imperative that the provided cover is used

Be particularly careful before touching the drive shaft directly or indirectly with your hands. This is only
allowed when the system is deenergized and the drive is stationary.

Safety devices must never be deactivated.

Relatively high leakage to ground occurs in the converter and the motor, i.e. the drive may be incom-
patible with current-operated e.l.c.b.s (corresponding to provisional standard EN 50178:1994 Section
5.2.11.2).

You may only use variable-speed drives in applications that correspond to valid EN specifications.

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Installation

5.2 Checks before installation

y Make a note of the type and number of the unit and of the motor
y Check the connections using the connection diagram
y Connect the plugs on the device:

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Installation

5.3 Display

LED display element

LED Color Function


H14 RS yellow Controller disable
H13 BB green Ready for use
H12 TBA red Overtemperature of ballast resistor *
H11 TMO red Overtemperature of motor
H10 UZK red Overvoltage in DC link
H9 SGR red Current limit reached
H8 FLG red Position encoder signal error
H7 IZK red Overcurrent in DC link
H6 UVS red Supply voltage too low
H5 FBS red BEDAS missing
H4 NMX red Maximum speed reached
H3 TKK red Overtemperature of heat sink
H2 FTO red Tachometer generator signal error
H1 FPH red Phase missing *

* Monitored in BUM 60 only

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Installation

5.4 Connection diagram

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Installation

Connection information

X6 1 External current limitation: wire bridge on X6:2 reduces current to 10% of Imax;
On request, variable current limitation (0 ... +10 V ¤ 0 ... 100% of current)

2 Frame ground to NC/PLC earth: at least 4 mm²

3, 4 Speed specified value nset = 0 ... 10 V on differential amplifier;


Polarity specified in the plan applies to counter-clockwise-rotating motor shaft

5, 6 Additional specified value, same differential amplifier as before, does not run via integrator

X7 Connect brushless tachometer generator via a cable set; for line lengths, refer to accessories.
For assignments of terminals 1-12, refer to connection diagram.
At initial commissioning, use an original cable.

X8 1, 2 Relay for programmable message

BUM 60 A - SM - 0100 all other BUM 60 A-Controller


Message overvoltage DC link
contact open in the event of a message contact closed in the event of a message
contacts 24 V / 1 A contacts 24 V / 1 A

3, 4 Ready for use relay; contact closed on ready for use, can be loaded with 24 V/1 A; relay opens approxi-
mately 2 s after switch-on and closes immediately after Mains OFF.
Error is indicated via the operating display if the relay drops in operation.

5, 6 Display of actual RPM value 0 ... approx. 10 V, bipolar; instrument for speed display Ri > 5 k

6 Reference potential BSa

7, 6 Current specified value for display of the current or the torque; output 0 ... 10 V corresponds to 0 ... peak
output current, output bipolar, can be loaded with 2 mA max.

8, 9 Reset, error messages are cleared on activation of the contact or, if not available, automatically on
switching on again. No reset until the error has been removed!

10, 11 Close the contact for controller enable; in the case of a controller disable (contact open), the system dis-
ables the controllers at once, the drive coasts to a stop (==> unbraked OFF). Alternative: when the con-
tact opens, the system automatically brakes the drive to zero speed, braking is interrupted after 200 ms
and the controller is disabled (==> braked OFF). For braked OFF, you must fit wire bridge W502 in
BEDAS.
In the case of drives with high levels of external inertia, it is better to slow the drive down to zero speed
using the RPM specified value and to disable the controller at zero speed. In the event of a power failure,
the system does not automatically brake drives to zero speed, but rather, they coast to a stop instead.

12, 13 Connection for the motor thermal relay; when the bimetal contact in the motor opens, the system carries
out controller disable and an unbraked OFF. This protects the motor from overloading.

X10 Slot for the operating data store, BEDAS; the device to motor assignment is indicated on the BEDAS.
For further information, refer to the Technical Data.

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Installation

5.5 Operating data store BEDAS

You plug this component into location X10 on the controller. BEDAS contains all the circuitry necessary
for adapting the power unit to the respective three-phase current motor. The great advantage is the ease
of handling at commissioning and maintenance. The marking on the device clearly defines the assign-
ment to the three-phase current servo motor and to the power unit.
Marking

BEDAS Operating data store

BUS 6 A Converter controller unit

Rated current in A and


10 - 54 rated voltage (540 V)

56 L 2
Servo motor three-phase
current

Maximum speed
1 for 1200 RPM
2 for 2000 RPM
3 for 3000 RPM
4 for 4000 RPM
6 for 6000 RPM
0 for special speeds 2 1 066
Speed specified value Serial number for component
adaptation fitting (specified at the factory)
1 for 4.3 V - 5.7 V
2 for 5.3 V - 6.7 V
3 for 6.3 V - 7.7 V
4 for 7.3 V - 8.7 V Operating mode (W502)
5 for 8.3 V - 9.7 V 0: Unbraked OFF
6 for 9.4 V - 10.9 V 1: Braked OFF
7 for 10.8 V - 12.2 V
0 for values out of series

Fitting the operating data store


(this may only be changed by specialist personnel after consulting with the manufacturer)

I²t 1 R221 24 Device-specific: do not change

Imax motor 2 R231 23 Only fitted if Imax motor < Imax device
W501 Do not change
BEDAS coding 3 22
nspec compensation 4 R110 21 Speed specified value adaptation
Limiting of integral Not normally fitted
action component 5 R152 20
P gain 6 R150 19 Matched to the controlled system without external inertia
Current limit 7 R245 18 Message "SGR" issued after 2 s if R=270 k
SGR reached
nact compensation 8 R113 17 Actual value adaptation to the rated speed of the motor
TH ramp-up time 9 R109 16 Without R109, minimum time, otherwise R > 1k

TN reset time 10 R151 15 Standard setting


W502 With wire bridge Braked OFF for all axes
Braked/Unbraked OFF 11 14
Imax external 12 R226 13 Wire bridge for analog input - 1 k for reduction to 10 %

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Installation

NOTE

Unit type BUM 60 A - SM - 0100 all other A-Controller


BEDAS The BEDAS code (W501) can be printed The BEDAS code (W501) must be printed with
with the values of the BUM 25 (27 kΩ) the value 22,1 kΩ.
BEDAS code.

Order information:

y Motor type and version


y Length and works number of tachometer generator cable
y Specified RPM speed for max. speed
y Ramp-up time of integrator for specified value step-change
y Braked OFF or Unbraked OFF with controller disable
y Switched or analog current limit

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Installation

5.6 Brushless tachometer generator cable


Three-phase current servo motor Brushless tachometer generator cable Controller

Plug 1 12-pin cable Plug X7

k 3 Black 1 k

Position encoder

l 5 Blue 2 l

m 4 Red 3 m

U-klm 2 Violet 4 +15 V

BSD 1 Grey/pink 7 BSD


Red/blue
U1 9 Brown 10 U1

BSn1 8 White 9 U0

U2 10 Yellow 11 U2
Tachometer
generator
BSn2 11 Green

BSn3 6 Pink

U3 7 Grey 12 U3

SE 12 8 SE
Connect screen
to motor housing
Pins 5 and 6 are not connected

Connect the sub-unit terminal to socket X7 on the controller. If necessary, unscrew the sub-unit terminal
before laying the cable.
Two different versions of the cable are supplied that are precut and have integrated Interconnectron PLD
171 circular plugs. You must only use original manufacturer parts that guarantee contact protection, ten-
sion relief, protection levels and permanent contact.

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Installation

Precut cables with connectors

Length Article number: Article number:


Standard Power chain
2m 113 580
3m 113 146 197 362
5m 102 124 194 122
7m 194 152
8m 110 620 195 502
10 m 102 125 195 503
15 m 102 126 195 504
20 m 110 433 195 505
25 m 110 844 195 506
30 m 112 220 198 666
35 m 113 579
44 m 197 419
50 m 112 155
60 m 112 759
65 m 197 048
75 m 197 049
100 m 188 349

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Installation

5.7 Accessories

Works number
y Sub-unit terminal
X6 6-pin RM 5 1900 9063
y Sub-unit terminal
X7 12-pin RM 5 1900 9064
y Sub-unit terminal
X8 13-pin RM 5 1901 7560

NOTE

A set of sub-unit terminals for X6 and X8 are supplied already fitted.


Sub-unit terminal X7 is supplied with the brushless tachometer generator cable.

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Commissioning

6 COMMISSIONING

6.1 Danger information

WARNING

This equipment carries a dangerously high voltage and, depending on the version, may have danger-
ous rotating parts (fans). Ignoring the safety and warning information may result in death, severe per-
sonal injury or damage to property.

You are responsible for mounting the power converter, the motor, the commutating reactor and any
other equipment in accordance with appropriate safety regulations (e.g. DIN, VDE); equally, you must
ensure that all other relevant national and local regulations are met with regard to cable ratings and
protection, grounding, disconnecters, overcurrent protection, etc.

The most important factors for protecting people are the DIN/VDE protective measures and safety reg-
ulations. If there are no protective earth connections on the equipment, commutating reactor or the
motor, personal injuries are inevitable, since the surfaces may carry dangerously high voltages.

The power converter's power cables are energized!

The mains unit and the field connector of the power converter carry a dangerous voltage even when
the main contactor has dropped.

During operation, the principles on which the power converter and the motor work lead to leakage cur-
rents to earth that are dissipated via the specified protective earths and may result in a current-oper-
ated e.l.c.b on the input side blowing prematurely.

In the case of a short-circuit to frame or to ground, a direct proportion may arise in the leakage current
that makes triggering a higher level current-operated e.l.c.b either more difficult or totally impossible.
Make the PE connection in accordance with DIN EN 60204/VDE 0113 Part 1/06.93; Section 8.2.2 tak-
ing into account provisional standard EN 50178/ VDE 0160/11.94, Sections 5.3.2.1 and 8.3.4.4.

Before carrying out commissioning, check whether the plastic covers over the power stage connec-
tions are in place.

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Commissioning

WARNING

If an error occurs, the drive is deenergized and then coasts unbraked to a standstill. You should con-
sider this situation particularly with motion and lifting drives.

Faulty drive response


During initial commissioning, faulty or uncontrolled motion of the driven machine elements is always
possible. At this stage, you should therefore proceed with particular care.

Before switching on the drive, you must carefully check the functions of all the higher level safety
equipment to prevent injury to people.

Take particular care when directly or indirectly touching the drive shaft with your hand. This is only al-
lowed when the shaft is stationary and the power converter is deenergized. Any exposed parts of the
machine, such as the shafts, fans, etc., must be covered during operation.

Contact protection in accordance with paragraph 4 Section 4 VBG 4


Protection against direct contact comprises all the measures against danger that can result from
touching the active parts of electrical equipment.
You must therefore protect the active parts from being touched by means of insulation, the construc-
tion and arrangement of the equipment or permanently mounted guards. The guards in question are
standard covers, barriers and procedures that guarantee that people cannot touch active parts that are
carrying power.

Switching cabinets must have an emergency off facility to switch off any voltages that could be dan-
gerous. This does not include equipment which, if switched off, would cause an even more dangerous
situation. The emergency off releasing element must be arranged in such a way that it can be reached
quickly in case of danger. In the case of work that is considerably more dangerous than usual, another
person must be present.

The machine minder must ensure that unauthorized people do not work at the machine.

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Commissioning

WARNING

The machine minder must report immediately any changes that occur at the machine which adversely
affect safety.

When dismounting safety equipment during commissioning, repair and maintenance work, you must
ensure that the machine is taken out of commission in accordance with applicable regulations. You
must remount and check safety equipment immediately after completing commissioning, repair and
maintenance work.

This list of measures required for safe power unit operation is not complete. If you should need further
information or if special problems arise please contact BAUMÜLLER NÜRNBERG or a sales agency.
Please observe the warnings in Chapter 1 of these operating instructions.

NOTE

Before touching the modules, the operator must release any electrostatic charge to protect electronic
components from high voltages generated through electrostatic charge, by simply touching a
conductive, grounded object immediately before, for example.

This label is placed in a visible location on units with electrostatically susceptible


components and / or modules.

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Commissioning

6.2 Initial commissioning of the drive system

NOTE

Did you observe the following points before carrying out initial commissioning?:
y made a note of the type and number of the devices and the motor
y checked the connections on the basis of the connection diagram, in particular correct connection
of the motor winding

NOTE

At the factory, we carefully checked the drive and optimized it using the operating data store. Changes
may be made to the operating data store only after consulting with the manufacturer.

DANGER

During initial commissioning, faulty or uncontrolled motion of the driven machine elements is always
possible. Before carrying out commissioning, you should therefore carefully check that all safety equip-
ment is functioning properly to rule out any chance of injury to people. Commissioning of the drive
should be carried out by authorized specialists who should assist the engineer in commissioning the
machine.

1. Check the assignment of the motor and the BEDAS and the power unit;
2. Check connections on the basis of the connection suggestion.
Carry out VDE protective measures!
Connect the following:
– Battery box with settable RPM specified value (e.g. 0 ... 1.5 V) at terminals X6:3 and 4; polarity
dependent on the required direction of rotation; refer to diagram (temporarily disconnect the ex-
isting connections for controller enable and RPM specified value);
– Voltmeter for checking the intermediate circuit voltage for the duration of commissioning;
– Push button for controller enable between terminals X8:10 and 11;
– 24 V for the holding brake in the motor (e.g. type DSG.....)
3. Motor checks
– Sequence of main connections
– Brushless tachometer generator cable is OK
– Connection of temperature monitoring
– Holding brake, if present
– PE connection
– Motor fixed to flange
– Shaft rotates easily

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Commissioning

– Check plug-in connection on motor


4. Limit the current to 10% of the peak device current, Imax (approximately 6 A) by connecting terminal
X6:1 to 2.
5. Unscrew connections L1, L2 and L3.
6. Check the mains voltage by connecting the voltmeter and switching it on.
7. Reconnect L1, L2, L3 on the basic unit.
8. Switch on the system.
Check the operating display.
(see display)
9. Check whether the fan is working.
10. Check the intermediate circuit voltage.
Switch off the system and wait until the DC link has discharged.
11. Release the holding brake if fitted.
Specify at terminals X6:3 and 4 the minimum RPM specified value of approximately 100 mV.
12. Switch on the system and briefly press the push button for controller enable:
– Yellow LED for controller disable goes out.
– Motor turns.
– Power transmission runs without disturbances.
– Direction of rotation OK
– Speed controller functioning (even motor running dependent on the specified value).
– Switch off the system!
Correct the direction of rotation by replacing both specified value cables.
13. Carry out coarse setting of the speed using a manual tachometer or frequency f of the position en-
coder signal at terminal X7:1 to X7:7 actual speed value nact = (f * 60)/3
Match the speed, using the specified value adaptation potentiometer, e.g. to an RPM specified value
of 500 mV.
14. Run in the drive while taking into account the final position or the maximum speed.
15. Check emergency stop.
16. Cancel current limitation by disconnecting X6:1 from 2.
17. Switch on again at RPM specified value nset = 0, carry out drift compensation using the Drift.
18. Using potentiometer P gain, increase the P gain as a proportion of external torque to motor torque
to just below the stability limit. You know that this limit has been reached when the specified cur-rent
value, IS, on terminal X8:7 starts oscillating. From this point onwards, turn the potentiometer down
slightly (to the left);
Note
Increasing the P gain in an uncontrolled manner does not improve the dynamics of the drive at all;
in continuous operation, the oscillations of the current specified value can lead to thermic overload
of the motor.
19. Switch off the system!
Remove the push buttons for controller enable and the battery box and make connections to the con-
troller instead.
20. Carry out fine compensation of the RPM by means of the screen display, contouring error, manual
tachometer or similar and correct the drift compensation;

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Baumüller Nürnberg GmbH 5.96012.02a
Commissioning

Correct the direction of rotation by reversing the connections for the RPM specified value if neces-
sary.

DANGER

With a higher-level position controller, positive feedback can lead to the drive rotating at maximum
speed. Additional measures must be taken to prevent positive feedback.

21. Check the dynamic response:


– Acceleration to rapid traverse (with/without load)
– Braking to n = 0 (check ballast, braking time)
– Position control
– Emergency stop
In each case, record the speed actual value nact (terminal X8:5) and the current specific value IS
at X8:7.
Even at extreme loading, the elasticity of the intermediate circuit voltage may only be 10%.
22. Does the torque curve ML (IS) correspond to the intended operating mode load?
23. The holding brake releases and brakes at the right time.
24. After one hour of continuous operation:
– Measure the temperatures of the switching cabinet and the motor with a probe!
– Temperature on flange < 65 °C
– Incoming air on converter < 35 °C (with cabinet closed)
– Mains failure/braking/emergency stop
– Limit switch
– Start/stop operation
Commissioning of the BUS 6 A/BUM 60 A is completed.

32 A-Controller
5.96012.02a Baumüller Nürnberg GmbH
Maintenance

7 MAINTENANCE

WARNING

The equipment carries a dangerously high voltage and has dangerous rotating parts (fans). Ignoring
the safety and warning information may result in death, severe personal injury or damage to property.

You may only carry out maintenance when the unit is deenergized.

Do not begin work on the power stage and the intermediate circuit until you have made sure that the
unit is not carrying potential or a voltage (remanent charge).

When dismounting safety devices during commissioning, repair and maintenance work, you must en-
sure that the machine is taken out of commission exactly as specified. You must remount and check
safety equipment immediately after completing commissioning, repair and maintenance work.

After carrying out any work involving intervention in the machine – regardless of whether this involves
the motor, the actual value acquisition or the power converter – the owner must carry out acceptance
testing and document it chronologically in the machine log. Failure to do this may result in the owner
being faced with consequences relating to liability legislation.

Do not start work on the power unit, intermediate circuit until you have made sure that the unit is not
carrying potential or a voltage (remanent charge).

7.1 Maintenance information

The units supplied are maintenance-free.

Prohibition of unauthorized modifications

For safety reasons, unauthorized additions or modifications to the drive are not allowed.

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Baumüller Nürnberg GmbH 5.96012.02a
Maintenance

7.2 Troubleshooting

Operation display Cause Remedy

1 FPH red Phase missing in feed * – Replace the defective fuse


– Check the mains connecting cable

2 FTO red Tachometer generator – Temporarily replace the defective tachometer generator ca-
signal error ble and repair the breakage (soldered or plug-in contact).

Missing tachometer gen- – Measure the resistance of the tachometer generator on the
erator voltage U1, U2 or metal plug:
U3 U1 between 8 and 9
U2 between 10 and 11
U3 between 6 and 7
(R = 47 Ω or 23.5 Ω)
Completely replace the motor

3 TKK red Over temperature of heat- – Power transistors are overloaded


sink – Fan has broken down
– Ambient temperature is too high
– Heat concentration in the cabinet

4 NMX red Maximum speed – Specified RPM value is too high


exceeded – Actual RPM value adapted wrongly

5 FBS red Missing BEDAS – Plug BEDAS into location X10 on the associated device
such that pins 1 and 24 on the device are at the top

6 UVS red Supply voltage is too low – Intermediate circuit voltage drops to U < 200 V
– With error in switching power supply, replace device and re-
tain BEDAS
7 IZK red Overcurrent in current cir- – Short-circuit of motor lines
cuit – Interturn fault in motor
– Earth fault in motor
8 FLG red Position encoder error – Temporarily replace the defective tachometer generator ca-
ble
repair the breakage (soldered or plug-in contact).
– Completely replace the motor

9 SGR red Current limit reached – Monitoring time for current limit set on BEDAS exceeded
– Monitoring time too short
– Motor blocked
– Motor lines interchanged
– Load torque too high
– Motor lines not connected
– Current limiting activated
– Tachometer generator or position encoder interchanged
– Brake blocked

10 UZK red Overvoltage in intermedi- – Connection voltage too high


ate circuit – Discharging of intermediate circuit via the ballast circuit
does not function
– Braking power > Pmax ballast
– Ballast resistor blown
– Wire bridge for ballast missing
– External ballast resistor not connected

11 TMO red Overtemperature of – Effective power on the shaft is greater than the motor's full-
motor (thermal relay must load power
be connected) * – Improve the cooling conditions, i.e. lower the temperature
and improve cooling on the flange
– Fan on the motor has broken down
– BEDAS fitted wrongly

34 A-Controller
5.96012.02a Baumüller Nürnberg GmbH
Maintenance

Operation display Cause Remedy

12 TBA red Overtemperature choke – Effective power on the shaft is greater than the motor's full-
resistor load power
– Improve the cooling conditions, i.e. lower the temperature
and improve cooling on the flange
– Fan on the motor has broken down
– BEDAS fitted wrongly

13 BB green Ready for use – no error

14 RS yellow Controller disable – no error

* only with BUM 60

NOTE

If no error message is pending but ready for use, BB, is not lit up, the basic unit is not ready for use.

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Baumüller Nürnberg GmbH 5.96012.02a
Maintenance

7.3 Disposal

For the most part, the equipment consists of the following components and materials:

Component Material

Various spacers, housing of current converter and unit fan, Plastic


etc.

PCBs on which all the open- and closed-loop electronics are Base material: Epoxy-resin fiberglass woven
mounted material, copper-coated on both sides and
plated-through, various electronic components
such as condensers, resistors, relays, semi-
conductors, etc.

For technical reasons, electronic components might need to contain dangerous materials, so you should
not open them.

If the components are used correctly, there is no danger to human beings or to the environment.

In case of fire, dangerous compounds may result or hazardous materials may be released.

You must dispose of or recycle equipment or components according to national regulations as well as
any applicable local or regional ordinances.

36 A-Controller
5.96012.02a Baumüller Nürnberg GmbH
Appendix

8 APPENDIX

8.1 Manufacturer Declaration

HERSTELLERERKLÄRUNG
IN SINNE DER
EG-MASCHINENRICHTLINIE 89/392/EWG, ANHANG IIB

Manufacturer Declaration in Accordance with


the EC-Machine Guidelines 89/392/EEC, Appendix II B

Hiermit erklären wir, daß es sich bei dieser Lieferung um die nachfolgend bezeichnete Maschinenkom-
ponente handelt und daß ihre Inbetriebnahme solange untersagt ist, bis festgestellt wurde, daß die Ma-
schine, in die diese Komponente eingebaut ist, den Bestimmungen der EG-Maschinenrichtlinie 89/392/
EWG, Anhang II B entspricht.

We herewith declare that this delivery includes the following specified machine component and that its
putting into operation is prohibited until the declaration is made that the machine, in which this compo-
nent is built in, complies with the regulations of the EC-machine guideline 89/392/EWG, appendix II B.

Bezeichnung der Maschinenkomponente: Typenbezeichnung:


Specification of the machine component: Type:

Regler BUS 6 A - SM
BUM 60 A - SM
Nürnberg, den 11.02.2005

Hersteller-Unterschrift:
Signature of the Manufacturer:

_________________________ _________________________
Andreas Baumüller ppa. Dr. Peter Heidrich
Geschäftsführer Entwicklungsleiter
Head of devision Head of development

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Baumüller Nürnberg GmbH 5.96012.02a
Appendix

8.2 General Conditions of Sale and Delivery

1. Obligation and Conclusion of Contract instructions of and at a cost to the purchaser. Upon
a) Deliveries of goods and provision of services shall be demand, the packaging material has to be returned with-
effected exclusively based on these trading conditions. out delay, free of freight charges and expenses.
They are an essential component of the contracts for 6. Dispatch and Passing of Risk
delivery and shall be considered as having been accepted Deliveries shall be made ex works. The dispatch shall be
by the placing of an order. In the case of constant busi- effected at a cost to and at the risk of the recipient of the
ness relations, they also apply for the future contracts. service/the purchaser. The risk passes to the recipient of
b) Agreements diverging from the contract and verbal collat- the delivery/purchaser as soon as the delivery items leave
eral agreements shall only be binding if they have been the works. This shall apply at the latest, from the transfer-
confirmed in writing by Baumüller Nürnberg GmbH (here- ral of the delivery items to the person carrying out the
inafter referred to as Baumüller). Diverging trading condi- transport, forwarding agent or carrier.
tions on the behalf of the purchaser shall be without
obligation, even where these have not been expressly 7. Warranty
a) The period of warranty amounts to 12 months from the
objected to. These General Conditions of Sale and Deliv-
day of dispatch.
ery shall be considered as having been accepted by the
purchaser at the latest when the delivery is accepted. In the event that a delivery item is defective, Baumüller
shall deliver an additional replacement or make a subse-
c) In as far as deliveries of goods are subject to separate
quent improvement at its own choice. Multiple subsequent
external obligations in accordance with the Law Concern-
ing Foreign Trade and Payments with respect to the Fed- improvements are permissible. Other warranty claims on
the behalf of the purchaser, in particular also due to direct
eral Office for Economics, the purchaser has to observe
or indirect consequential damage are excluded. The pre-
the relevant conditions at his/her own responsibility.
condition for any warranty is the normal contractual use of
2. Price and Offers the delivery items. In the event of the utilization of war-
Offers are subject to confirmation, not binding and apply ranty services, the motor, the replacement part or the
subject to material supply possibilities. Supplements and device has to be sent in free of freight charges, packaging
amendments require written confirmation. Prices are ex costs or customs duties after prior co-ordination with
works and are subject to confirmation. Invoicing takes Baumüller. Baumüller is exempted from any warranty if
place in accordance with the prices valid on the date of the party ordering returns the goods complained about
delivery. without prior co-ordination or contrary to agreement. War-
3. Extent of Delivery and Delivery Time ranty claims expire one month after rejection of a defect
a) Specified delivery periods/dates are without obligation, in on which notice is given, in as far as the purchaser
as far as nothing else to the contrary has been expressly remains silent in this respect.
agreed upon in writing. Delivery periods do not commence 8. Notification of Defects
until the purchaser has fulfilled all duties of co-operation, a) The purchaser shall examine the subject matter of the
in particular regarding details of performance. In the event contract and delivery items immediately and give notice of
that the agreed deposits for orders are delayed, then the any defects without delay, however, no later than 7 days
delivery time shall be extended accordingly. after receipt of the delivery. In case of non-obvious
b) The purchaser is entitled, in particular in the event of a defects notice has to be given in writing without delay after
delay in delivery of longer than 3 months, to set an appro- their discovery, however, no later than 6 months from the
priate period of grace and after its expiry, to withdraw from point of delivery. In the event that the purchaser does not
the order. Claims to compensation due to non-fulfilment or give notice of any defects in writing within this period of
delay shall be excluded, in as far as Baumüller is not time, then the subject matter of the contract shall be con-
responsible for intent or gross negligence. sidered as having been approved.
c) Baumüller is entitled at any time to effect partial deliveries b) The purchaser shall allow Baumüller a suitable inspection
and partial services, as well as to invoice these accord- of defects of which notice is given and shall place all nec-
ingly. essary/requested technical information, in particular,
4. Delivery Problems inspection records and test reports at Baumüller's dis-
a) Delays/preventions in the delivery of goods or the provi- posal. In the event that the purchaser fails to do so, then
sion of services due to force majeure entitle Baumüller to the delivery items shall be considered as not having been
delay the production and delivery by the duration of the complained about and as being approved. In the event
obstruction plus an appropriate period of time or to with- that the purchaser alters the delivery items, then he/she
draw in part or in whole from the order. shall lose his/her warranty claims.
b) Industrial disputes or other circumstances which substan- c) In the event of an established material defect or perfor-
tially impede or render impossible the delivery, such as, in mance defect, Baumüller can eliminate the defect or sup-
particular, disturbances in the operating processes, prob- ply a replacement. The purchaser can demand rescission
lems in procuring materials, official directives also apply or a reduction after the expiry of an appropriately set
as force majeure, irrespective of whether they arise with period of grace. Further claims on the behalf of the pur-
regard to Baumüller or suppliers. chaser, in particular to the reimbursement of dismantling
c) In these cases, Items 4 a), b), the purchaser shall have no costs or installation costs are excluded. The same applies
claim to compensation due to non-fulfilment or delay of to damages which do not affect the delivery item itself.
the delivery. d) Natural wear and tear and damage which arises after the
5. Packaging transferral of risk, in particular also due to incorrect or neg-
Items for sale and delivery items are packaged and trans- ligent handling, excessive demands or other unsuitable
port insurance policies are taken out according to the use not in conformity with the contract are excluded from

38 A-Controller
5.96012.02a Baumüller Nürnberg GmbH
Appendix

the warranty. The same applies in particular for defects d) The authorization on the behalf of the purchaser to dis-
which are attributable to atmospheric discharges, over- pose of the reserved goods and to collect assigned claims
voltages and chemical influences. expires in the event that the terms of payment are not
e) If no case of warranty is in existence or in the event that complied with, in particular, also in the case of bill and
this subsequently turns out to be the case, the purchaser cheque protests. In this case, Baumüller is entitled to take
shall remunerate the utilization or the use of an item or of possession of the reserved goods. The purchaser bears
a right, as well as services provided and expenses to an the costs incurred by this. The taking back of goods shall
appropriate amount. Baumüller is entitled to a right of con- only represent a withdrawal from the contract when this is
trol as referred to in §§ 315 ff. BGB [German Civil Code]. expressly stated.
9. Liability e) In the event that the value of the securities granted
Contractual or legal claims on the behalf of the purchaser exceeds the secured claims in terms of amount by more
against Baumüller are limited to intent and gross negli- than 20 %, then Baumüller shall renounce the securities
gence. This does not apply in as far as claims from the exceeding this value.
ProdHaftG [Product Liability Act] have been enforced. 12. Drawings and Documentation
Baumüller shall only be held liable to the amount of the Baumüller is entitled to the exclusive property right and
damage foreseeable in accordance with the purpose of copyright to cost estimates, drawings and all other docu-
the contract. Material damage which exceeds the value of mentation. These documents may not be made accessi-
a delivery/service is not foreseeable in this sense. The lia- ble to third parties without prior written consent. In the
bility is limited in terms of amount to the remuneration con- event that a contract is not concluded, not implemented or
tractually owed. otherwise ended, then all documents have to be returned
10. Payments immediately and unsolicited. There shall be no right to
a) Invoices are payable at the time agreed in the contract, at retention to these documents.
the latest within 30 days after the invoice date, in cash and 13. Copyright (in particular Software / Licence)
without deductions. The purchaser can only offset with a) Baumüller is exclusively entitled to all rights to the soft-
claims which are final and absolute or undisputed. The ware/edited versions, in particular property rights and
same applies to the exercising of rights of retention. copyrights to the relinquished software, in particular for
b) In the event of a delay in payment on the behalf of the pur- the controlling of machines, systems and installations.
chaser, interest to the rate of 4 % above the respective b) Baumüller grants the purchaser/buyer the non-exclusive,
minimum lending rate of the German Federal Bank, how- non-transferable right to use the relinquished software in
ever at least 10 % has to be paid, without separate proof the framework of the contractual purpose at the contractu-
being required. ally intended location/on the places in existence at the
c) Failure to comply with the terms of payment or circum- time of purchase (single licence). The software shall only
stances which endanger the credit worthiness of the pur- be used on the associated purchased contractual item.
chaser result in all claims immediately becoming due. In Any use extending beyond this is prohibited. In the event
these cases, deliveries shall only be made against pay- of a use extending beyond this, Baumüller shall have the
ment in advance. rights referred to in Items 13 c), 13 d).
d) Cash payments, bank transfers or cheque and bill pay- c) It is prohibited to make copies of the relinquished soft-
ments shall not be considered as payment/fulfilment of the ware, whether in whole or in part, in as far as the making
obligation before the amount due for payment has been of copies of the machine-readable material in the frame-
irrevocably received by Baumüller or credited to work of the required data backup or as copies for internal
Baumüller's account. company use has not separately been agreed upon with
e) Payments have to be made directly to Baumüller. The field prior written consent from Baumüller. Processing of the
staff are not entitled to accept payments or to issue exten- relinquished software, in particular by means of alteration,
sions or waivers without separate written authority. translation or by bundling with other programs shall only
11. Reservation of Ownership be permitted after prior written consent from Baumüller.
a) The ownership of delivery items remains reserved up to Protection notices from Baumüller on/in the software may
the fulfilment of all existing claims against the purchaser not be removed and also have to be adopted onto copies
from the business relation. Any bundling with other items and edited versions. Copies produced contrary to this con-
shall be effected by the purchaser for Baumüller. Then, dition shall come under the possession and copyright of
the entire product shall be considered as reserved goods. Baumüller. Baumüller can prohibit the use of such copies
b) The purchaser is entitled to sell the reserved goods in and elect to demand the immediate surrender or complete
orderly business transactions. All claims to which the pur- destruction with proof of this destruction.
chaser is entitled from this sale or other legal grounds d) The buyer is not permitted to extend the licence in terms of
shall be assigned by him/her in advance to Baumüller. location/work places/machines/machine types or to grant
Baumüller shall accept the assignment. In the event that rights of utilization or grant sub-licences. The extension of
the reserved goods are bundled or sold with other items the licence shall be permitted by Baumüller exclusively
standing in the possession of third parties, then the against a separate remuneration which has to be agreed
assignment shall only apply to the amount of the invoice upon in writing.
value of the reserved goods. The purchaser is authorised 14. Applicable Law
to collect these assigned claims. Upon request, he/she The law of the Federal Republic of Germany is authorita-
has to make notice of the assignment to the debtor. tive for all rights and obligations from and in connection
c) The purchaser shall inform Baumüller without delay of with this contract. The regulations of the UN Sales Con-
impending and enforced access on the behalf of third par- vention (CISG) are excluded.
ties to the reserved goods or to the assigned claims. The 15. Place of Performance and Place of Jurisdiction
purchaser shall bear the costs incurred by this. The place of performance for delivery and payment is the
seat of Baumüller. The place of jurisdiction for all dispu-

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Baumüller Nürnberg GmbH 5.96012.02a
Appendix

tes from and in connection with this contract, in particular quired to carry out the acceptance. This also applies in the
also for cheque and bill liabilities is the seat of Baumüller. event that the purchaser refuses the functional test/the
16. Miscellaneous acceptance without sufficient cause.
In the event that individual or several conditions of these e) Experts to be designated by both parties shall take part in
Conditions of Sale and Delivery should be or become inef- the acceptance inspection. The result of the functional test
fective in part or in whole, then the validity of the remain- shall be entered in a record to be signed by the purchaser
ing conditions shall remain unaffected by this. The parties in consideration of the technical specifications.
shall complement/replace the ineffective or incomplete 18. Erection and Installation
condition with an appropriate regulation which most exten- Erection and installation shall only be effected in the case
sively corresponds to the economic purpose of the con- of express agreement at the following further conditions:
tractually desired regulation. The same applies for the a) The purchaser makes required workers and material avail-
case of the presence of a gap in the regulations. able at his/her own expense.
For the case that acceptance and installation are also b) Before the commencement of installation works the pur-
agreed upon, then the following conditions, Items 17 and chaser shall make available unsolicited all required speci-
18 shall also apply: fications, in particular concerning the location of power
17. Acceptance lines which have been laid such that they are hidden and
a) The inspection of the delivery items ready for acceptance similar installations, as well as the required static specifi-
shall take place in the Baumüller works. The purchaser cations.
shall bear the costs of this inspection. In the event that the c) Before the commencement of the erection/installation, the
purchaser fails to perform the inspection, then the delivery delivery items required for the commencement of works
items shall be considered as having been delivered in have to be on site and all preliminary works progressed to
conformity with the contract when they leave the works. the extent that the erection/installation can immediately
b) The purchaser is obliged to take delivery of goods and begin and be completely carried out without interruption.
services from Baumüller without delay. Immaterial defects d) In the event that the erection, installation or putting into
do not entitle the purchaser to refuse the acceptance. operation is delayed due to circumstances for which
c) In the event that the purchaser does not declare within 7 Baumüller is not responsible, then the purchaser shall
days after notification of the readiness for acceptance on bear the costs for idle time and journeys required on the
the behalf of Baumüller or after receipt of the contractual behalf of the installation personnel.
service in writing and with exact, examinable specification e) The installation personnel working time has to be certified
of reasons that he/she refuses the acceptance, then the weekly by the purchaser. The purchaser shall present to
acceptance shall be considered as having been declared the installation personnel a written certification regarding
and the orderly performance of the contract as having the ending of the erection/installation without delay.
been ascertained. f) Baumüller shall not be held liable for the installation per-
d) The agreed service shall be considered as having been sonnel works, in as far as the works are not connected to
accepted when the item delivered has been put into oper- the delivery and the erection or installation.
ation by the purchaser himself/herself or upon his/her g) Trial runs on systems not supplied by Baumüller shall not
instructions by third parties beyond the functional test re- be carried out by the installation personnel.

40 A-Controller
5.96012.02a Baumüller Nürnberg GmbH
8.3 Index
C
Commissioning 27
Connection diagram 20
Controller enable 10
D
Dimensions 15
Display 19
Disposal 36
E
Electrical Data 10
G
General Conditions of Sale and Delivery 38
I
Initial commissioning 30
Installation 17, 18
M
Maintenance 33
Maintenance information 33
S
Speed set value 10
T
Technical Data 9
Transportation 13
Type code 11
U
Unpacking 13

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42 A-Controller
5.96012.02a Baumüller Nürnberg GmbH
Baumüller Nürnberg GmbH Ostendstraße 80-90 90482 Nürnberg T: +49(0)911-5432-0 F: +49(0)911-5432-130 www.baumueller.de

All information given in this manual is customer information, subject to change without notice. We reserve the right to futher develop and actualize
our products continuously using our permanent revision service. Please notice, that specifications/data/information are current values according to the printing date.
These statements are not legally binding according to the measurement, computation and calculations. Before you make any information given in this manual to the basis
of your own calculations and/or applications, please make sure that you have the latest edition of the information in hand.
No liability can be accepted concerning the correctness of the information.